Mattress construction



Aug 14 1945vs. MARsAcK 2,382,496'

MATTRESS CONSTRUCTION Filed uarc'h'zz, 1943 Patented Aug. 14, 1945MATTRESS CONSTRUCTION Sam Marsack, Milwaukee, Wis.,

assigner to Marsack Patents Corporation, Milwaukee, Wis.,

a corporation of Delaware Application March 22, 1943, Serial No. 479,989

2 Claims.

My invention relates to a mattress comprising an inner resilient coreenclosed in a suitable container which is in turn enclosed within anouter cover in one or both of the faces and at the sides and ends, andmore particularly relates to an improved mattress construction withoutthe usual metallic spring construction and to the method of making thesame.

The invention has among its objects the production of an attractive,comfortable, durable and satisfactory mattress of the kind described,which will maintain its shape and its original appearance as when new,and compare favorably in every respect with any previous type ofmattress construction. Comfort, durability and retaining its shape andattractiveness are the essential requisites of a good mattress, and allthese features are present in the herein described mattress.

Among its further objects is the construction of a mattress which inmanufacture can be made up without requiring essential material requiredfer war purposes, or if essential material, requiring aY minimum of thesame, and by a minimum labor requirement by workers, male or female, andwithout special skill or aptitude. Also it has as a furthery object aconstruction of mattress and method of making the same which permitsquantity production of a succession of mattresses, all identical orsimilar in appearence, durability and comfort characteristics.

A further object is to produce a mattress with a core which willmaintain its shape, and yet will not be hard and unyielding and with atop covering which will afford comfortable rest to the user, the samebeing so constructed and assembled that the mattress is strengthened andreinforced throughout the edges, and Will retain a trim andsubstantially square edge Without the necessity of a separate externalor internal roll at the edges.

A still further object is the provision of an outer covering for the topand bottom, or for either alone, in the form of a quilt or pad,constructed to provide transversely depressed zones across the mattresswhen the mattress is completed. affording an attractive and ornamentalappearance, which pads may be secured to the core along the depressedZones as Well as at the sides and ends of the core. This also obviatesthe use of tufting extending to the faces of the mattress, whereby themattress may be kept clean since a plurality of the usual tuftingdepressions which are hard to clean out are not present, lit being asimple matter to brush out the straight depressed zones to removeaccumulated dust or dirt.

Many other objects and advantages of the construction herein shown anddescribed will be obvious to those skilled `in the art from thedisclosure herein given. v

To this end, my invention consists in the novel construction,arrangement and combination of parts herein shown and described, andmore particularly pointed out in the claims. i

In the drawing, wherein like reference characters indicate like orcorresponding parts:

Fig. l is a perspective view of a completed mattress;

Fig. 2 is a sectional view taken substantially on line 2 2 of Fig. l;

Fig. 3 is a sectional view of a portion of the mattress partiallycompleted illustrating the method of filling the same; and

Fig. 4 is a sectional View taken substantially" on the line 4--4 of Fig.1.

Referring to the drawing, the preferred construction consists of aninner lling or core of felt, hair or any similar material which issatisfactory for the purpose. This is arranged within an inner casingand the unit then covered by a quilted filled pad or blanket, areversible mattress being provided with a pad or outer quilted blanketon the opposite faces-that is to say, the top and bottom.

Referring particularly to Fig. 2, l represents the inner filling and 2and 3 top and bottom cover sheets connected to a border or boxing memberat the sides and ends, forming a bag or container. In the particularmattress illustrated the sides and ends are formed by a padded boxingindicated generally by the numeral 4 made up of an inner ply 5, an outerply 6 and an intermediate filling 1. Where desired, the inner ply 6 andfilling 1 may be omitted, and the boxing consist of a single ply 6, orthe boxing may consist only of ply 6 and filling 1. I have illustratedin Fig. 1 how the boxing may be construct-ed with stitching 8 securingthe plies andV lling together, it being obvious that any equivalent suchas eyelets or the like may be employed for the purpose, and wherestitching is used that it may be run vertically or lengthwise of theboxing or form ornamental designs. One of the cover sheets, as shownsheet 2, is provided with a flap 2 constituting a part of the coversheet and initially not connected at its inner free edge to the body ofthe cover 2 until the mattress is lled, as will be more fully explainedhereinafter. The cover plies are stitched or otherwise secured at theiredges to the edges of the boxing as indicated at 9 in which stitching isshown, and the two sheets 2 and 3 are further connected by tufting tiesI0 extending through the filling I as shown in Figs. 2 and 4. Upon thecompletion of the lling of the mattress the free edge of flap 2 and thecover sheet 2 are secured together by a lacing or stitching II.

There is arrangeda quilt, blanket or pad, in the construction shown,over the two sheets 2 and 3, this pad consisting of filling I3 arrangedbetween the sheets I2 and I4, the pad being quilted or tufted bystitches I5. As shown in Figs. 2 and 4, these ties also secure flaps I1which are connected by means of the lacings I8 to the inner body coversheets 2 and 3, preferably in line with one of the lines of tufting I0.The cover sheets I2 and I4 of the pad are secured together at theiredges and to the boxing by means of the tape 20 and stitching 2 I.

In making up the mattress a bag or container is rst made up of thesheets 2 and 3 and boxing,

the ap 2'- being turned back as indicated in Fig. 3,'v and the fillingmaterial inserted in any suitable manner within the casing through theopening formed adjacent flap 2' until the body ofthe mattress is wellstuffed and ready for the tufting. After this the flap 2 and body sheet2 are secured together by means of the lacing or stitching II coveringthe opening. The tufting cords III extending in rows across the mattressand fromend to end are then applied in the usual manner, it beingunderstood that any style of tufting or tufting buttons may be used.Then the pad constructed by arranging the sheets I2 and I4 with thefilling I3 therebetween and quilted or tufted by means of the stitchesI5. At this time the aps I1 are secured to the pad by the stitching I5.Each of the pads is then in order applied to the body of the mattressand the flaps I1 laced to the body or core of the mattress by thelacings I8, as most clearly shown in Fig. 4. After this, the edges ofthe sheets I2 and I4 are brought together with the edges of the boxingplies `5 and 6 and the same bound by the tape 20 and stitches 2| aroundthe mattress, first one side or face, and then the mattress turnedover'and the opposite side similarly secured.

The core or filling I of the body of the mattress may be more or lessrigid or rm with the pads somewhatsofter. It will be thus seen that Ihave an inner core construction covered by pads, the parts'beingsuitably secured together forming a durable and comfortable mattresswhich will hold its shape and not bulge. In applying the stitching I5across the pads the line of stitching forms more or less of a creaseacross the mattress, giving the effect of a plurality of cushions, asshown. triple cushions. The construction is not only economical tomanufacture, but is particularly attractive and very durable andsatisfactory. As previously mentioned, edge rolls, either inner or outerare not required to secure a trim square edge, and by eliminating metalspring constructions an essential material for war needs is saved forthat purpose. l

Having thus described my invention, it is obvi- `ous that Variousimmaterial modifications may be made in the same without departing fromthe spirit of my invention; hence I do not wish to be understood aslimiting myself to the exact form, construction, arrangement andcombination of parts herein shown and described, or uses mentioned.

What I claim as new and desire to secure by Letters Patent is:

1. In a mattress of the kind described, a yieldable core provided withfilling material and cover sheets at the top and bottom thereof,multiply boxing consisting of inner and outer plies with a llinginterposed between the same, said boxing extending around the sides andends of the core, said cover sheets being secured to said lling materialbetween the ends thereof by lines of tufting, a pad for the topconsisting of two pad cover sheets with intermediate yieldable fillingmaterial and stitched together at spaced points, iiaps secured to theinner face of the pad at said stitching, lacing means for securing thesaid flaps to the adjacent cover sheet and attached core at lines oftufting, said cover sheets at their edges being secured to the adjacentedges of the inner and outer plies of the boxing.

2. The method of constructing a mattress consisting in rst making acontainer consisting of a boxing and cover sheets, one cover sheethaving a temporary opening therein, lling said container through saidopening with yieldable lling material, then closing the opening andextending tufting cords through the filling material connecting thecover sheets, providing a pad consisting of cover sheets and a yieldablefilling, securing the filling and cover sheets of the pad together bystitching the same across the same from side to side and securing a flapto the pad during said stitching, securing the flap to the adjacentcover sheet of the container along the lines of tufting whereby the padis brought in close relation to the container to provide a depression inthe pad simulating a line of demarcation between associated cushions,then securing the pad cover sheets at their edges to the edges of theboxing.

SAM MARSACK.

